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English

Film Processor
Operation Manual

Machine No.:

Type:

PROTEC GmbH & Co. KG


In den Dorfwiesen 14, D-71720 Oberstenfeld, Germany
Telephone: +49-7062-9255-0 e-mail: service@protec-med.com

Installation Date:

Status:

Subject to change

08-2009/1.7

EU-Declaration of Conformity

EU-Declaration of Conformity
PROTEC declares, that the product
Description:

OPTIMAX2010

Machine type:

X-Ray-Film Processor

Model no.

116x-y-0000
x is a number between 0 and 9, y is a number between 1 and 9

conforms to the following harmonized standards:


Safety:

IEC 61010-1:2001 + A1:92 + A2:95; DIN 1988 T4:12/1988; UL 3101-1; CSA 22.2-1010-1

EMC:

EN 50081 Part 1, 03/1993; EN 50082 Part 1, 03/1993

according to the regulations of:

the Medical Device Directive 93/42/EEC Class 1,

the Low Voltage Directive 73/23/EEC and the

EMC Directive 89/336/EG

PROTEC GmbH & Co. KG, Lichtenberger Strasse 35, D-71720 Oberstenfeld, Germany
Supplementary guidelines:

DIMDI: DE / 0000042967

WEEE: DE 55471807

Location and date of issue


Oberstenfeld, 2. July 2007, Jochen Krupp (Technical Manager Analogue Systems)

OPTIMAX2010

Table of Contents

Table of Contents
Introduction .......................................................................................................... 7
Intended Use......................................................................................................... 8

English

Technical Specifications ..................................................................................... 8


Safety Instructions............................................................................................... 9
Installation .......................................................................................................... 10
Initial Operation.................................................................................................. 13
Operation
Short Overview and Control Panel .............................................................. 14
Switching the Machine On........................................................................... 16
Automatic mode........................................................................................... 16
Anti-crystallisation function / Time replenishment ....................................... 16
Working Parameters .................................................................................... 17
Machine Cover Safety Disconnection.......................................................... 19
Auto fill Function .......................................................................................... 19
Manual Mode............................................................................................... 20
Water Saving Mode ..................................................................................... 20
Stop Film Transport ..................................................................................... 20
Rollfilms and Paper Films ............................................................................ 21
Use of Memory Function ............................................................................. 21
Care
Daily Care.................................................................................................... 22
Weekly Care ................................................................................................ 22
Thorough Cleaning ...................................................................................... 23
Maintenance / Disposal ..................................................................................... 24
Problems and Solutions
Advice on Film Defects................................................................................ 27
Advice on Machine Errors ........................................................................... 28
Error messages ........................................................................................... 29
Accessories ........................................................................................................ 30
Service Manual as appendix, see page page 33
Optimax 2010 with 2 pumps see starting page 53
Copyright
2008 by PROTEC. All rights reserved. Any reproduction that violates the limitations set forth by copyright law, needs to be authorised in writing by PROTEC.
Information on Liability
This manual has been checked for correctness. The instructions and specifications
were correct at the time it was published. Future models may have modifications
without prior notice.
PROTEC does not take responsibility for damage caused directly or indirectly by
error, omission or non-conformity of the manual.

Introduction
You are the proud owner of a modern, automatic processor. Due to the precision
roller transport system, both sheet and roll films can be processed. The automatic
film registration is activated immediately when a film is fed in. The film materials are
developed, fixed, rinsed and dried. With the easy to operate micro-processor, the
processing conditions can be adjusted to suit the various film and chemical types.
The developing solutions are temperature-regulated, circulated and automatically
replenished.
These Operating Instructions contain important instructions for installation, operation and servicing of the machine. Please read the provided information carefully to
ensure reliable and satisfactory operation of your film processor.

OPTIMAX2010

Technical Specifications

Intended Use
The X-ray film processor OPTIMAX2010 is intended exclusively for the purpose
describe in the introduction above.
X-ray film processors (MDD class I) are employed in medical applications (medical products directive) and non-medical applications (electrical appliances and
EMC directives).
Intended use includes observing the operating instructions, the installation instructions and adherence to the safety notes.
Any application differing from intended use voids the guarantee by PROTEC.
The owner of the machine will be liable for damages resulting from unintended use
or faulty application.
Intended use includes adherence to all statutory regulations concerning occupational safety and radiation protection applicable at the operating site.

Technical Specifications
Film transport:

Continuous roller transport system

Film formats:

In general: Sheet and roll films up to 35.8 cm


(14.1 ) width;
Roll films with leader from 70 mm (2.8 ) width;
Smallest film format 10x10 cm (4x4 ).
Mammography type 1161: For processing mammography films.
Graphics-art type 1162: With cassette box
(LxWxH) 35x13x12 cm (13.8x5.1x4.7) for
processing roll films.

Processing capacity:

129 films 24x30 cm (10x12 ) per hour


(standard unit, film transverse, at 90 s)

Process time:

1.5-3 min.; adjustable in steps of 0.1-min.

Linear speed:

28-56 cm/min., depending on selected cycle time.

Developing time:

25-49 s, depending on selected cycle time.

Tank capacities:

Developer, fixer and water tank 5 litres each

Circulation system:

Developer and fixer are continuously circulated by


a circulation pump

Replenishment:

Automatic by film surface measurement in relation


to processed film; replenishment can be switched
off; time replenishment can be activated.

Developer temperature:

Adjustable 28 - 37 C (82.4 - 98.6 F)

Fixer temperature:

Adjusted to developer temperature by heat


exchanger.

Dryer temperature:

Adjustable between 10 - 99% of dryer output, temperature achieved depends on line voltage.

Water connection:

Permissible water pressure 2 - 10 bar (29 - 145


psi), permissible water temperature 5 - 30 C (41 86 F).

Water consumption:

1.9 litre per minute when processing.


Water saving mode: 0.9 litres per minute

Drain capacity:

7 litres per minute

Noise level:

Less than 58 dB(A).

Heat emission:

During processing approx. 1.4 kJ/s.

OPTIMAX2010

Environmental conditions:

1 Temperature 18 - 40 C (51.6 - 104 F), ventilated room, room temperature should be lower
than set bath temperature.
2 Relative humidity lower than 80 % up to 31 C
(88 F), linearly decreasing to 50 % at 40 C
(104 F)
3 Height above sea level less than 2000 m (6666
ft.)
4 Indoor use

Pollution degree:

System protection:

IP 20

Electrical connections:

Electrical specifications are indicated on the model


nameplate.
Type116x-1-y000: 230 V~ 10 %, 8.8 A, 50 Hz.
Type 116x-2-y000: 230 V~ 10 %, 8.8 A, 60 Hz.
unit conforms to IEC 1010 (EN 61010, VDE 0411)
overvoltate category II
Type 116x-4-0000: 110 / 120 V~ 10 %, 12 A, 60
Hz.
unit conforms to UL 3101 and CSA 22.2-1010
overvoltate category II

Power consumption:

Stand-by: 0.12 kWh


Processing: 1.4 kWh

Weight (unit):

Empty 35 kg (77 lbs)


Filled 50 kg (110 lbs)

Dimensions (LxWxH):

77x59x42 (** 112) cm (30.3x23.2x16.5 (** 44.1))

Floor space required:

0.45 m2 (4.8 sqft)

English

Technical Specifications

** Height incl. optional working table or base cabinet.

Safety Instructions
To ensure the safe operation of this processor, installation and use should always
conform to the instructions contained in this manual.
The developer and fixer chemicals used in the processor should be handled
according to the manufacturers instructions. In general: Undiluted chemicals are
caustic. For this reason, chemicals should be handled very carefully. Avoid contact with skin, always wear protective clothing, gloves and glasses when handling
the chemicals - for example, when mixing and refilling. Also when taking the
racks out for cleaning or servicing. If chemicals have come in your eyes, rinse the
eyes immediately with cold, running water for approximately 15 minutes and contact a medical doctor afterwards. Inhalation of chemicals can be dangerous to
your health and should be avoided. For this reason, always ensure that the room
in which the processor is installed is adequately ventilated.
Environmental regulations regarding the storage and disposal of waste chemicals should be obtained from the local water authorities and complied with.

Before opening the unit, switch off the unit and unplug it from the electrical
socket. Service and repairs must be performed by trained service technicians
only. Use only manufacturers replacement parts.

OPTIMAX2010

Installation

Installation
1. Requirements for installation
a.

Fresh water connection: Shut-off tap, thread with 3/4" outside diameter (washing machine connection), Water pressure 2 - 10 bar (29 - 145 psi).

b.

Drainage connection: Plastic tube - inner diameter 50 mm (2) or larger. A


ventilated syphon which serves as odour preventor should be included in the
planning. The drainage tubes should be installed with a decline of minimum
5 %.
Local Water Authorities regulations should be complied with.

c.

Electrical connection: Fused wall socket with earth connection according to


electrical data (see technical specifications, page 9). It is also required to
install an earth-leakage switch (with 25 A / 30 mA nominal error current).
Electrical connections should be carried out according to regulations by an electrician.

2. Transport
Due to the weight and dimensions of the film processor, OPTIMAX2010 should
always be carried by two persons. To do so, hold the machine at the sides on the
bottom (see figure). While putting the machine down, watch the position of the levelling feet to prevent damaging these.

3. Set-Up
Unpack the Processor. Remove cover and transport securing brackets on the sides
of the roller racks. Remove roller racks - start with the dryer rack.
The standard version of OPTIMAX2010 is delivered as a tabletop processor with
a three part base plate. If the machine is upgraded with the optional stand or cabinet, the two side parts must be removed from the base plate.
Table-top installation
If the unit is to be set up on a table top or work table, only the four unit feet need to
be screwed out and levelled..
Attention!
Machine should not be installed on table-top without adjustable feet. as this would block the ventilation openings under the
machine and cause overheating.
Installing on processor stand or base cabinet
In the event that the processor is to be installed on the stand or cabinet (optional
accessory), the processor will be mounted directly to it. Mount processor according
to manual included with stand or cabinet (the adjustable feet inside the accessory
bag are not required). Remove the two side parts of the base plate before.
Finally the processor needs to be levelled:
Place spirit level across the sidewalls of processor and adjust the levelling feet accordingly. Replace the racks into the processor and close the latches.

10

OPTIMAX2010

Installation

min. 70 cm (27.5)

English

4. Connecting the processor

Drainage
and collecting
containers

Water connection:
Fit water-inlet hose (grey) at the rear of the machine and connect to the prepared
fresh water supply.
Water overflow:
The water overflow hose ( = 16 mm) is likewise connected at the rear of the unit.
The hose is installed as described in the next section.
Remark:
There are two options for installation of the water overflow at the front of the unit.
Install the pre-assembled hose in the unit and connect it to the overflow outlet at the
unit front. Upon delivery this outlet connection is a dummy only (see graphics on the
top right).
All other hoses (see diagram page 12): Connect the enclosed hoses according to
colour system onto the front of the machine. Put hose clip (enclosed in accessory
bag) over hose end, before attaching to connection. Warm up hose end (with hot
water or lighter) and push onto the respective connection. Finally push clip over
hose and connection.
Cut hoses to required length. Then integrate the stop cocks into the three drainage
hoses in such a position, that they are easy to reach.
Connect the suction pipes to the hose ends for the replenishment tanks using hose
clips. Put the suction pipes through the cover opening into the respective replenishment tanks and snap them in.
The overflow and drainage hoses from the developer and fixer should be guided
into their respective collecting containers. The overflow and the drainage of the water can either be guided into the drainage syphon or into respective collection containers.

OPTIMAX2010

11

Installation

Hose Connections

Optional

DEV

DEV

FIX

Replenishment tanks

Overflow
Outlet

Outlet

Outlet

FIX

Replenishment tanks

DEV

Overflow

FIX

Overflow

H2O

Pay attention to the correct colour connections:


Developer:
red;
Fixer:
blue;
Water:
clear

Replenishment
Overflow
Outlet

Danger of Overflow!
Use the included cable ties (accessory bag) to secure the hoses. Fix all hose ends which lead into the syphon or collecting
container, so that they do not drop into the liquid - otherwise
liquid may overflow.

Very important:
The hose piping should be straight (without the hoses going
up and down) with a constant decline. The hoses should be as
short as possible and without bends and kinks. This is very
important for the water overflow hose. Bad piping work will
cause the machine to overflow!
Inform yourself of the local water board regulations regarding
drainage. These regulations may differ from information in
this manual, but they should be complied with.
If the machine is installed table-top, ensure that the table is
stable enough and does not wobble.

12

OPTIMAX2010

Initial Operation

Initial Operation
Test run

a.

Close the three drainage stop cocks and fill the tanks and replenishment containers with water. Open water inflow tap. Connect electrical socket and
switch the machine on. Water now flows into water tank. The circulation pump
activates, however the hosing of the machine must be ventilated.

b.

Ventilation of the replenishment pump:


Switch to the manual mode and switch on the replenishment pump. Let the
pump run until no more bubbles rise inside the tanks.

c.

Ventilation of the circulation pump:


The circulation pump runs after switching on the machine and ventilates itself.
If this should not work, a loud running noise will be heard. Switch the machine
off again. Open the stop cocks of the developer and fixer for five seconds and
switch machine on again. Repeat this procedure until no more air bubbles are
visible in the developer and fixer baths and until the circulation pump runs quietly.

d.

Check all hose connections for leakage. Switch machine off and drain water
out.

English

Important!
Processor should not be run dry!
Upon commissioning and every refilling the pumps must be
vented.

Filling the Processor with Chemicals


Prepare chemicals inside the replenishment containers according to manufacturers
instructions.
Filling the processor manually
By using a suitable container, pour chemicals into the respective tanks. First the fixer and then the developer. Caution: when filling, be sure that chemicals do no
splash from one bath into another. When fixer solution is mixed with developer solution, the developer chemical is destroyed.
Caution! When filling the unit manually, be sure not to allow liquid to flow into the
slot of the cover switch or onto the operating panel. This may damage parts.
Snap each suction pipe into the respective cover of its replenishment container and
close it carefully. Place containers under processor.
Using replenishment pump
Filling of processor can also be done by use of the replenishment pump (this takes
much more time). The chemicals containers need to be filled manually with at least
1.0 litres of fresh chemicals, to ensure the pumps will not run dry. Snap each suction
pipe into the respective cover of its replenishment container and close it carefully.
Place containers under processor. Activate the filling process by means of the automatic tank filling function. The function stops automatically as soon as the set level has been reached. Latest after 20 minutes, the function will shut off automatically.
Limitation: The function may fill up tanks of developer and fixer to different levels. If
this happens, then use a suitable container to fill up the tanks completely.
Warning, hot surface!

OPTIMAX2010

13

Operation

Operation
Short Overview and Control Panel
Display working parameters

! Arrow button Up = increase parameter value


" Arrow button down = decrease parameter value

Mode Buttons

# Processing time in minutes


$ Developer temperature in C
% Dryer output in %
& Replenishment time in seconds

Power on Autofill

Enter Memory
Recall

Store

Exit

Important!
Safety function stops film transportation when cover is removed. Therefore keep cover placed on the machine when
processing films.
*When processing roll films in cassettes, pull approx. 15 cm of film out of the cassette and fold the corners (see page 21). Place cassette into cassette box and feed
film into the infeed. Only machines with cassette box.
Light protection cover

Film input

Control panel

*Roll film
cassette

Developing
Film
switch

Power switch

14

Replenishment Developer

OPTIMAX2010

Operation

Attention:

English

Upon first operation and each refilling of a developer check


the function of the circulation pump and vent the pump if required (see page 9).
Before use...
1.

Close water-drainage stop cock.

2.

Open water tap.

3.

Switch processor on.

4.

Check liquid level in replenishment and drainage collecting containers.

5.

Wait until the start-cycle has been completed or until Developer temperature
is reached.

6.

Run cleaning films through processor.

Working procedure
7.

Processing films:
Open the light protection cover, insert the film on the left of the feed tray, during the feeding please watch the Film-feed-display .

After work...
8.

Switch the unit off.

9.

Close water tap.

10. Open water drainage stop cock

Stand-by mode:
When no film is being processed, the machine switches to Stand-by. The chemicals
remain at a constant temperature. The film transport and water inflow activate at intervals to avoid crystallisation of the chemicals on the transport rollers. Entry of the
next film is possible at any time.
Film exit
Do not place any
object on the processor.

Drying

Fixing

Washing

Fresh water inflow


Replenishment fixer

OPTIMAX2010

Height-adjustable feet

15

Operation

Switching the Machine On


Before switching the machine on, open the fresh water tap and close the water
drainage tap (under control panel). Then switch the machine on (main switch is situated under the control panel). Once the machine is switched on, a Start-cycle of
eight minutes duration is activated: A replenishment cycle is carried out, the water
tank fills automatically and the chemical baths heat up. During this Start-cycle no
films can be fed into the machine. The display shows two bars when the processor is not ready and no films can be fed in. This is the case during the start-cycle
and also when the baths have not reached the temperature. Until the developer
temperature is not reached, the developer temperature button (5) is flashing. It is
possible that the chemical bath has not reached the required temperature even after the Start-cycle has been completed. You need to wait until the developer temperature is reached, before inserting films. Wait until the bars disappear from
the display.

Automatic mode
After completion of the Start-cycle and after a film-processing, the machine automatically goes into the stand-by mode. In the stand-by mode the processor can be
started at any time by placing a film into infeed tray. Note that films can only be processed when the developer temperature is reached. When the display shows two
bars no films can be fed into the machine. The temperature in the bath is too
high or too low. However, when a film was fed into the machine, two bars with decimal points . .. To avoid a jamming of films wait before feeding the next film in
until this display disappears (which is also signalled by an acoustic sound).
A film in the feed-tray is registered by two film detection switches and the machine
starts up. The film is pulled into the machine and transported through the developer,
fixer and water baths. The remaining time of processing i.e. until the film finally
leaves the machine is displayed, when no more film is in the infeed-tray and the
processing time button was pressed. Each working-parameter can be called up on
the display by pressing the respective mode-button, however, during processing,
parameters cannot be altered. The temperatures of the developer and dryer are automatically regulated by the controller. The replenishment rate of developer and fixer chemicals is activated according to the processed film-surface (film-surface
measurement). The dryer is heated to the set value. Inside the dryer, the film is
dried and then normally output onto the cover. The machine then goes into the
stand-by mode. To keep the machine in working condition during the stand-by
mode, the electronics have been furnished with two specialities: The Anticrystallisation Function and the Time Replenishment.

Anti-crystallisation function
In stand-by mode, the film transport, the dryer ventilation are activated every
20 minutes for a period of 20 seconds. This prevents the build-up of crystals on the
rollers. This function cannot be switched off.

Time replenishment (Anti oxidation function, Flood


replenishment)
Also during the stand-by, the developer chemicals are subject to change which
causes their deterioration. By means of the time replenishment, a replenishment cycle is activated after 60 minutes without replenishment. With this function, the quality of the developer chemicals are maintained even when standing idle for long
periods. The time replenishment function can be deactivated.

16

OPTIMAX2010

Operation

1.

Switch the unit off.

2.

Press the buttons processing time (4) and replenishment time (7) simultaneously and keep pressed.

3.

Switch the machine on again and release the pressed buttons.

4.

Switch the time replenishment on or off with the cursor keys (2 and 3). If you
enter 0, time replenishment is off, 1 switches it on.

5.

Switch the unit off to save the settings.

English

Setting of time-replenishment:

Working Parameters
The processing machine develops, fixes, rinses and dries the film materials automatically. The film and chemical requirements can be adjusted accordingly and
stored in the control unit.
Display of working parameters:
1.

Switch processor on.

2.

Press the respective mode button (4-7) and keep it pressed to display the set
value.

Press the respective mode button (4-7) and let it go to display the current actual value.
Setting the working parameters:
1.

Switch processor on.

2.

Machine must be in the stand-by mode and no film must be in the processor.

3.

Press the respective mode button (4-7) and keep pressed: The display shows
the set working parameter.

4.

Change value by means of the arrow buttons (2 and 3) until required value
appears on the display. The upward arrow button (2) increases and the downward arrow button (3) decreases the value.

5.

Release the mode button.

Processing time
The processing time, is the time, it takes the front end of a film from the infeed of
the processor until it reaches the film exit. The processing time is set by the speed
with which the film is transported through the machine. Depending on the requirements, this time can be varied from to 1.5 minutes (90 seconds) to 3 minutes, adjustable in 0.1-minute-steps (Adjusting the processing time: see Working
Parameters on page 17).
Processing and developer time relation
Processing time (min)
1.5
1.7
2.0
2.3
2.5
2.7
3.0

OPTIMAX2010

Developer time (s)


25
28
33
38
41
44
49

Infeed speed (cm/min)


56
49
42
37
34
31
28

17

Operation

Developer temperature
The developer temperature of the different film-materials depends on the developing time. The faster a film has to be developed, the higher the temperature must be.
The developer temperature can be set between 28-37 C according to the individual
requirements (Setting the developer temperature: see Setting the working parameters: on page 17). If the temperature of the developer bath is lower or higher than
the set value, then the developer temperature button (5) is flashing and the display
shows two bars . Before feeding a film into the machine, wait until the temperature has been reached and the displayed bars disappear.
The following chart shows guiding value relations between developer temperatures
and processing times. Variations are possible depending on the various films and
chemicals.
Processing time and developer temperature relation
Total processing time (min (s))
1.5 (90)
2.0 (120)
2.3 (138)
2.5 (150)
3.0 (180)

Developer temperature (C)


33 - 35
32 - 34
31 - 33
31 - 33
30 - 32

Dryer temperature
The dryer temperature cannot be set in degrees Celsius. However the dryer output
can be set in a range between 10-99 % (100 %), to adapt it to the film material to
be processed. 95 for example, corresponds to 95 % of the maximum output of the
dryer heating. To avoid dryer spots on the film, the dryer output may not be set too
high. Adjust the temperature so that the film just gets dry (Setting the dryer temperature: see Working Parameters on page 17).
Remark: Depending on mains voltage, dryer temperatures above 65 C may under
certain circumstances not be reached. The information in the table below are mere
guiding values. Different combinations of film material, chemicals and ambient conditions may require different dryer output settings.
Processing time and dryer output
Total processing time (min (s))
1.5 (90)
2.0 (120)
2.3 (138)
2.5 (150)
3.0 (180)

Dryer output (%)


85 - 99
75 - 95
65 - 85
55 - 75
45 - 65

Replenishment time
The replenishment of the developer and fixer chemicals is automatic. By means of
the film detection switches at the film-feed, the surface of the processed films is calculated and after 0.25 m2 film a replenishment cycle is automatically activated. The
replenishing volume can be set by means of the replenishment time. The replenishment time may be set in a range of 10-99 s. The replenishment can be switched off
by entering 0. This is advisable in rare cases only.

18

OPTIMAX2010

Operation

The chart below shows the replenishment time to be set for the requested replenisher rate per m2-film surface. The standard setting is 40 sec. with 600 ml replenisher rate per m2 film surface. The replenisher rate has to be adjusted depending
on film material, chemicals and film throughput.

English

Relation of replenishment time and replenisher volume


Replenishment time
Replenisher rate
Replenisher volume
(s)
(ml per cycle)
(ml/m2)
150
10
37.5
300
20
75
450
30
112.5
600
40
150
750
50
187.5
900
60
225
1050
70
262.5
1200
80
300
1350
90
337.5
1485
99
371.3
Values for pump setting 100 % supply volume or for to 85 % for 60 Hz supply.

Machine Cover Safety Disconnection


The machine cover may only be removed for service and maintenance purposes.
The processor cannot be started without the cover. In the event that the machine
cover is removed during film-throughput, the film transport will be stopped. On the
display the error message E1 will be displayed. This will render the film unsuitable.
The error will be reset when the machine cover is reinstalled. Thereafter the motor
may run a little faster for a short time.

Auto fill Function


In case new chemicals have to be filled into the processor (after installation, tank
cleaning), the tanks can be filled automatically by means of the auto fill function.
In the process, the tank is filled for a fixed period of 20 minutes, that is, chemicals
are pumped from the replenishment containers to the tanks. Also the water bath
will be filled (3 min. period). The display will show two symbolized tanks (see
right). When the auto fill function has been completed, the machine enters the
stand-by mode. If the respective baths are full before the time is up, the auto fill
function can be stopped manually. The level switch in the developer bath detect a
full bath and switches the pump off. The automatic tank filling can also be terminated manually.
Starting up the auto fill function:
1.

Switch the unit off.

2.

Press and hold the replenishment time button (7), switch the unit on.

Manual cancellation of the Auto fill function:


1.

Press and hold the replenishment time button (7) and press arrow down button (3).

OPTIMAX2010

19

Operation

Manual Mode
In the manual mode, the processor works without the film detection switches. The
film transport has to be started and stopped manually. All the set values in the manual mode are also valid in the automatic mode. Please note that the Infeeding-filmdisplay ( ) is deactivated. Replenishment continues to operate based on detection of the film surface processed. Only if the film detection switches are activated,
will film measurement be performed. In the manual mode, a replenishment cycle
can also be activated manually.
Switching to manual mode:
Switch the machine on. During stand-by, press the arrow-buttons up (2) and
down (3) simultaneously. When in manual mode the display is flashing.
Switching back to automatic mode:
In manual mode with film transport off press both arrow-buttons up (2) and down
(3) simultaneously.
Manual starting and stopping the film transport:
1.

Switch to manual mode.

2.

Press the processing time button (4) - the button illuminates.

3.

Start the film transport by pressing the arrow-button up (2) or stop the film
transport by pressing the arrow-button down (3).

Manual replenishment:
1.

Switch to manual mode.

2.

Press the replenishment time button (7) - the button illuminates.

3.

Start the replenishment cycle by pressing the arrow-button up (2) or cancel


the replenishment cycle by pressing the arrow-button down (3).

Water Saving Mode


The water saving mode reduces the water consumption. If the water saving mode
is activated, exactly 50 % less water is consumed.
Activating the water saving mode:
1.

Switch the unit off.

2.

Press and hold the buttons processing time (4) and dryer output (6) simultaneously.

3.

Switch the machine on again and release the pressed buttons.

4.

Switch the water saving mode off or on with the arrow buttons (2 and 3). If you
enter 0, the water saving mode is off; if you set 1, it is on.

5.

Switch the unit of to save the settings.

Stop Film Transport


In a case of a film-jam inside the machine, the film transportation can be manually
interrupted. To stop the film transport press both arrow-buttons (2 and 3) simultaneously. Related topics:
see Manual starting and stopping the film transport: on page 20
see Film is caught up in the racks on page 29

OPTIMAX 2010 with 2 pumps see description starting on


page 53.

20

OPTIMAX2010

Operation

Rollfilms and Paper Films

English

Roll films with a polyester lead of at least 10 cm length can be transported. The
adhesion must be chemical resistant.
Roll films without lead and paper-films must be folded on the corners, as shown
in the diagram, before being fed into the machine.

Use of Memory Function


In the memory two sets of parameters can be stored and be recalled to the operating memory.
Store processing parameters
1. Set machine to preferable parameters e.g. bath temperature, processing
time etc. (see manual).
2.

Press buttons 4 and 5 Enter Memory simultaneously to enter the memory


mode.

3.

Use the buttons 2 and 3 Select to select the parameter memory (P1 or P2).
These save the parameters, old values will be overwritten.

4.

Press the button 5 Store to store parameters and to leave the memory
mode.

Power on Autofill

Enter Memory
Recall

Store

Exit

Recall processing parameters


1. Press buttons 4 and 5 Enter Memory simultaneously to enter memory
mode.
2.

Use the buttons 2 and 3 Select to select the parameter memory (P1 or P2)
from which the parameters are to be recalled.

3.

Press button 4 Recall to recall parameters (copy into the operating memory) and to leave the memory mode.

To leave memory mode without change


Press button 6 Exit.
Choose the same bath temperature for all stored programmes. Of course different bath temperatures can be stored too, but when changing the programme you
always have to wait until the changed bath temperature is reached.

OPTIMAX2010

21

Care

Care
Daily Care
Before use...
1.

Remove dirt and dust from film-infeed with soft cloth.

2.

Run 2 - 3 cleaner films through the processor to remove all accumulated dirt
and dust from the rollers.

3.

Check the liquid level in the replenishment containers and if necessary refill.

After use...
When working has been completed at the end of the day, the water must be drained
from the machine. This reduces the growth of algae in the water bath. For that purpose open the water drainage stop cock (see page 12 bottom).
Attention: Do not let any liquid drop inside the processor or
run over the control. Liquids may cause damage to the processor.

Weekly Care
The developer chemicals cause residue build-up in the machine. This residue has
a negative effect on the developing process of the film material. For this reason the
processor has to be regularly cleaned of this residue.
Do a weekly clean of the roller racks, which only takes a few minutes.
1.

Switch machine off and remove cover.

2.

Loosen the securing latches of the roller racks (red, blue and beige) of the
drive shafts of each roller rack at the right side.

3.

Rinse all racks thoroughly under warm running water and then leave to drain
off. Use a soft sponge (do not use a scouring-pad, as this would scratch the
rollers!) and remove the dirt from the rollers. During this procedure, the rollers
can be turned by turning the drive shaft.

4.

Wipe the infeed-roller-pair (first roller-pair of developer rack) dry.

5.

Replace the racks: red = developer, blue = fixer, beige = water / dryer. Ensure
that the racks are firmly installed and do not forget to close the securing
latches on the drive shafts.

6.

Replace machine cover and ensure it is securely closed.

7.

Clean processor outer casing with damp cloth. Do not use aggressive cleaners or solvents.
Please note:
When removing the rinsing / drying roller-rack, ensure that no
water gets into the film dryer air channel.

22

OPTIMAX2010

Care

Thorough Cleaning

English

Depending on the quantity of films processed, a thorough cleaning is necessary


every 3 - 6 months. Tank cleaners are available for developer and water baths. The
fixer bath is cleaned with water. When preparing chemical tank cleaners, follow
manufacturer's instructions explicitly.
How to proceed:
1.

Switch the machine off and empty all tanks by opening the stop cocks.
Attention! Machine will not drain off, if it is switched on.

2.

Remove machine cover. When all tanks are emptied, close stop cocks again.
Now fill the fixer-tank with water. Prepare cleaner solutions for developer and
water baths and fill into respective tanks.

3.

Remove suction pipes from the replenishment containers and place them in a
water filled bucket. Attention! Do not add chemical cleaners here!

4.

Close machine cover and switch machine on.

5.

Start the film transport (see Manual starting and stopping the film transport:
on page 20) and keep running for 10 to 20 minutes. During this the installed
roller racks will be cleaned.

6.

Important: After completion of tank cleaning, the tank should be rinsed thoroughly with clean water. To do this, fill the machine with fresh water twice and
each time, let the machine run for a 10 minute period. Empty the tanks and reclose the stop cocks.

7.

Take out the roller-racks and rinse them thoroughly with running water.
Remove remaining dirt from the rollers by using a sponge and clean thoroughly. Doing this, the rollers can be turned by turning the drive shaft. Wipe
the infeed-roller-pair (first roller-pair of developer rack) dry. Replace the racks.

8.

Refill the tanks with respective chemicals. This can be done by hand or automatically (see Auto fill Function on page 19). Replace the suction pipes into
the replenisher containers. In certain circumstances the circulation system
must be ventilated: see Test run on page 13 item b).

9.

For quality check, process test films.

Before you go on holiday...


or in the event that your processor will not be in use for longer than two weeks, all
the chemicals have to be emptied out of the tanks. In case you don't want to do a
complete tank cleaning at once, then fill the tanks after emptying, with water.
Attention: Do not use alcohol containing solvents to clean the
machine!

The colour changes in the baths is normal; it is caused by the


properties of the chemicals!

OPTIMAX2010

23

Maintenance / Disposal

Maintenance / Disposal
Maintenance Protocol
Installation
Name:
Technician:
Telephone:

Machine type:
Training:
Date:

Serial number:
by:
Guarantee until:

Developer temp.:
Dev. reg. volume:
Developer:
Changed by:

Dryer temp.:
Dev. reg. volume:
Fixer:
Date:

Cycle time:
Anti-oxidation:
Film type:

Developer temp.:
Dev. reg. volume:
Developer:
Changed by:

Dryer temp.:
Dev. reg. volume:
Fixer:
Date:

Cycle time:
Anti-oxidation:
Film type:

Developer temp.:
Dev. reg. volume:
Developer:
Changed by:

Dryer temp.:
Dev. reg. volume:
Fixer:
Date:

Cycle time:
Anti-oxidation:
Film type:

Parameters Set

Maintenance work performed (see page 25)


Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

Maintenance
work
performed
Date:
Name:
next maintenance:

24

OPTIMAX2010

Maintenance / Disposal

Attention:
Never start the machine up unless it is filled with liquid!

1.

Functional check
film intake / film transport / replenishment / bath heating / dryer heating / water supply

2.

Cleaning
2.1.

Switch off machine, remove cover

2.2.

Empty all three tanks

2.3.

Close drain cocks and fill tanks with water

2.4.

Install cover, switch machine on

2.5.

Fill two additional vessels with water, put suction pipes into these vessels and activate replenishment for at
least two minutes (to remove residues of chemicals from replenishing hoses)

2.6.

Switch machine on for a few minutes

2.7.

Switch machine off

2.8.

Empty all tanks

2.9.

Prepare tank cleaning agent for developer and water tank according to manufacturers instructions

English

Recommended Maintenance Work:

Attention:
Do not use chlorine containing cleaning agents!

2.10. Fill developer and water tank with tank cleaning agent (do not use the replenishment pumps to do so)
2.11. Fill fixer tank with water
2.12. Place suction pipes into empty tanks
2.13. Install cover, switch machine on
2.14. Wait until the operating temperature is reached, approx. 30 C (observe information concerning temperature,
time, cleaning procedure contained in the data sheet of the tank cleaning agent)
2.15. Activate manual programme and transport
2.16. After approx. 15 minutes (observe information concerning temperature, time, cleaning procedure contained in
the data sheet of the tank cleaning agent) switch film transport off
2.17. Remove cover, neutralise developer tank (observe information concerning temperature, time, cleaning procedure contained in the data sheet of the tank cleaning agent)
2.18. Switch machine off
2.19. Empty all three tanks
2.20. Fill machine with water and switch it on
2.21. Put suction pipes into vessels with water
2.22. Activate regeneration pumps for at least five minutes
2.23. Check all pumps for tightness
2.24. Switch machine off
2.25. Drain tanks
2.26. Fill tanks 3/4 with water
2.27. Switch machine on
2.28. Activate replenishment pumps manually until tanks overflow
2.29. Activate film transport for a few minutes
2.30. Switch machine off and drain all three tanks

OPTIMAX2010

25

Maintenance / Disposal

2.31. Repeat item 2.20 to 2.30 if required (observe information e. g. concerning temperature, time and cleaning procedure outlined in tank cleaner data sheet)
2.32. Remove roller racks from the machine and remove dirt under flowing water using a soft rag or sponge
2.33. Clean all toothed gear wheels, axles, bearings and rollers, check them for damage (replace if required)
2.34. Demount the cover sheet of the film intake and clean it using a soft rag
2.35. Clean inlet plate using a soft rag
2.36. Mount the cover sheet of the film intake
2.37. Align roller racks and re-insert them in machine
2.38. Fill machine with chemicals
2.39. Switch machine on
2.40. Adjust bath temperature to previously adjusted value
2.41. Feed cleaning film (approx. 4 pieces)
2.42. Check function as described under item 1
2.43. Approx. 15 minutes after reaching of the set bath temperature, measure it for confirmation and re-calibrate if
required (see operating manual page 39)
2.44. Perform sensitometric test
Be sure to dipose properly of used machines.
Used machine contain valuable materials that should be recycled
and turned over for proper treatment. Please be sure to turn used
machines over to approved recycling centres.

26

OPTIMAX2010

Problems and Solutions

Problems and Solutions


Advice on Film Defects

English

Your processor has been constructed for long term use. However, if irregularities
occur, you will find help to locate the problem below. Please check the listed points,
before calling your service-technician.

Films do not have enough density

Bath temperature is too low.


Developing time too short.
Exposure time is too short.
Replenishment rate of developer too low.
Developer chemicals are exhausted: Renew.
Fixer solution has been mixed into developer: Renew. Clean and rinse bath
well before refilling.
Circulation is broken down.

Too high a density

Bath temperature too high.


Developing time too long.
Exposure time is too long.
Replenishment rate of developer too high.
Developer chemicals are too high diluted: Renew.
After renewing chemicals: Starter is missing.
Circulation is broken down.

Films will not dry

If warm air comes out of air channel in the dryer, chemicals and film type
should be checked.
Fixer solution is exhausted or diluted.

Film has a yellow-green surface

Not fixed correctly. Check the film type and fixer chemistry.
Fixer solution is exhausted or diluted. Replenishment rate of fixer is too low.

Scratches, pressure marks, dirt on film

Prior to processing films, run cleaner films through the processor.


Pressure marks caused by careless handling, finger nails etc.
Rollers are polluted. Clean tanks and roller racks.

Cloudy film

Level in developer is too low.


First guide bar of fixer rack is dirty (condensate or crystals). Clean rollerracks.
Developer is old or circulation not working.
Try processing films by infeeding them with emulsion side up.

OPTIMAX2010

27

Problems and Solutions

Advice on Machine Errors


Unit does not switch on

Ensure that electrical plug is firmly inserted into socket. Ensure that the electrical socket is supplying power by testing with an appliance e.g. a table light.

Rinsing water does not flow

Open water inflow tap.

The water pressure in the water supply system is too low: Pressure in the
plumping system too low: Minimum pressure has to be 2 bar (29 psi).

Replenishment rate too high

Check the programmed times of replenishment cycle and replenishment time.

Replenishment rate too low

Check the programmed times of replenishment cycle and replenishment time.

Check whether the machine can be started by means of each of the two film
detection switches in the feed slot. If one of the film detection switches is
defective, call your service technician. In the meantime, double the programmed replenishment time.

Replenishment pump does not pump

Check whether the replenishment containers are full and that the end of the
suction pipe is positioned under the liquid level.

Check whether there is air in the replenishment pipes. The replenishment


hose is aspirating air. Check the hose connections.

Water tank overflows

Water drainage hose (overflow) is bent. The hose end should be positioned
above the drainage level in the syphon.

Check water drain opening in the tank and the hose for blockage and residues. The drainage hoses should have a constant fall.

The film does not transport correctly

Film is fed in and gets caught in the machine: Check the positioning of the
racks in the machine and make sure that the latches are closed.

Film cannot be fed, the display shows E1

Close machine cover securely, paying special attention that the switch on the
rear of the control panel is actuated.

Film is in the infeed and nothing happens

Display is flashing: Control is in the manual mode. Switch back to Automatic


Mode (see page 20).

Insert the film into the film feed so it passes the film detection switches. Feed
the film to activate one of the switches. If the unit should not start, activate the
other switch. If the processor still does not start, call your service technician.
In the meantime, with limitations the processor may be operated in the Manual Mode (see page 20).

28

OPTIMAX2010

Problems and Solutions

Switch machine off and remove cover.

Check in which rack the film is caught up in and remove the respective rack.

If possible, catch hold of the film end by hand and by manually turning the
drive-shaft, pull the film out of the rack.

Replace the rack and secure with fastener. Replace machine cover and
switch the machine on again.

If a film is caught up in the machine due to a power cut, it can be transported


out of the machine by activating the transport with a film in the infeed
(machine can also be started up in the manual mode, see Manual starting
and stopping the film transport: on page 20).

English

Film is caught up in the racks

Important notes:
Ensure correct seating of roller racks; keep the lock closed at
all times.
Dont operate processor with empty replenishment tanks.
After a long machine shut down check bath level and refill if
necessary.

Error messages
Machine errors are shown on the display as abbreviations. The cause of error is explained below. For service technician: problem solution see Trouble shooting in
service manual.
Display

Cause and possible correction

E1

Cover switch is not actuated. Place cover correctly on the


machine and ensure that the cover switch behind the control
panel is actuated. If the error cannot be corrected, then the
cover switch may be broken.

UU

Too low level of the developer bath. Check the level and fill up
by pumping manually or refilling manually.

OPTIMAX2010

29

Accessories

The PROMIX A40 is a fully automatic chemical mixing machine for preparing
developer and fixer bath chemicals of either powder form or liquid concentrates.
All stages are guided and controlled by means of a microprocessor. Thanks to a
large reserve tank, up to 3 machines can be connected and continue to operate,
without having to interrupt the working process.
Due to its patented construction, the PROMIX A40 is easy to operate, reliable,
fast and virtually service free.
The PROMIX A40 replaces the usual replenishment tanks in the darkroom.
Ask your local dealer for more information.

Technical Specifications
Tank capacities:

each 20, 25, 30 or 40 litres

Reserve tank:

each 13 litres

Water connection:

3/4", 2 - 10 bar (29 - 145 psi)

Pump capacity:

38 l/min

Mixing times:

variable, 2, 3, 5, 10, 15, 20, 25, 30 minutes

Power source:

220-240 VAC, 200 W, 50/60 Hz Fuse: sb 2


A / 250 V

Weight:

28 kg empty, 108 kg full

Dimensions:

(WxHxD) 65 x 93 x 44 cm

30

OPTIMAX2010

English

Accessories

At last you can breathe again


AIRCLEAN 200 cleans the air from your processor. Unpleasant chemical odours
are absorbed through the large active charcoal filter. Allergies are prevented and
you can breathe again freely.
Simple installation directly on to the processor (no breaking through the wall).
Filter exchange cheap and fast approx. every 3 months.
Ask your local dealer for more information.

Technical Specifications
Cleaning capacity:

approx. 200 m3/hour

Filter:

Active charcoal

Power consumption:

43 W

Power source:

220-240 V, 50/60 Hz

Weight:

7 kg

Casing:

Stainless steel, plastic coated

Casing dimensions:

(WxHxD) 21 x 63 x 17 cm

OPTIMAX2010

31

Accessories

32

OPTIMAX2010

Service Manual
Table of Contents

English

Installation Data ................................................................................................. 34


Trouble Shooting ............................................................................................... 36
Spare Parts List.................................................................................................. 41
Electric Diagrams............................................................................................... 48
OPTIMAX 2010 NDT ........................................................................................... 54

OPTIMAX2010

33

Installation Data

Installation Data

Optional worktable or
closed cabinet (accessories)

1.

2.

Wall socket
220-240 V, 16 A resp. 110 V,
15 A (depending on machine
model). Power lead should be
equipped with Earth-Leakage
Switch, 25 A / 30 mA nominal
error-current. In addition, a
power control switch can be
installed.

Fresh water connection 3/4


with stop cock, permissible
pressure 2-10 bar, water temperature 5-25 C.

3.

Drainage plastic pipe PVC


50 mm (2) incl. syphon.

4.

Drainage resp. collecting containers for used developer.

5.

Darkroom

Sink
Drainage resp. collecting con- 60 x 40 cm (24 x 16)
tainers for used fixer.

6.

Storing space for replenishment tanks: Below machine or


externally.

7.

Ventilation of darkroom is necessary.

8.

Sink with freshwater and flexible hose. Interior dimensions


minimum (LxWxH)
60x40x30 cm (24x16x12).

3
6

Measures and positions are recommendations

34

OPTIMAX2010

Installation Data

Blind plate
1266-0-0001

All dimensions in mm.


Heights applicable in connection with PROTEC worktable
1267-0-0030.
Counter plate
1266-0-0002

Counter sunk screw M4x12


3079-8-5033

Bottom edge of
wall plate

Film exit height

Detail X

1.

Wall opening according to drawing.

2.

Fasten wall plate with enclosed eight screws (note markings).

3.

Fix blind plate with screws and straps on the film outlet (Detail X).

4.

Push processor up against wall plate and place foam rubber light protection
between processor and wall plate.

5.

Hang in film catch basket at wall plate from the backside.

6.

Check mounting-set for light im-permeability and function.

Wall break through


for film exit

Please note:
Pull sealing wedge off before removing machine cover.

OPTIMAX2010

35

English

Through the wall mounting film output


- Film output to the light room for OPTIMAX2010 type 116x-y-6000

Trouble Shooting

Trouble Shooting
Summary
1
2

6
7
8

Algae ............................................................................................................ 36
1.1 Excessive algae growth in water tank.................................................... 36
General......................................................................................................... 37
2.1 Unit does not switch on.......................................................................... 37
2.2 No display but circulation pumps run..................................................... 37
Drive ............................................................................................................. 37
3.1 Film transport does not run, film processing has started ....................... 37
3.2 Machine does not start automatically .................................................... 37
3.3 Machine doesn't stop automatically, motor and fan run continuously ... 37
3.4 Drive motor does not run ....................................................................... 37
Baths ............................................................................................................ 38
4.1 No circulation in bath ............................................................................. 38
4.2 Developer temperature too high ............................................................ 38
4.3 Developer temperature too low.............................................................. 38
4.4 Developer temperature too low, fixer temperature too high................... 38
4.5 Developer bath temperature too high or too low
(display shows values of 21 C or 40 C) .............................................. 78
4.6 Switch-over from C to F ...................................................................... 38
4.7 Calibration of bath temperature / actual bath temperature is different from
displayed value ...................................................................................... 38
4.8 Developer level switch constantly displays UU ................................... 39
Film Defects................................................................................................. 39
5.1 Films will not dry .................................................................................... 39
5.2 The film does not transport correctly ..................................................... 39
5.3 Scratches, pressure marks, dirt on film ................................................. 39
Replenishment ............................................................................................ 40
6.1 Replenishment pump does not work or works insufficiently .................. 40
Dryer............................................................................................................. 40
7.1 Dryer fan does not run or runs with too low speed ................................ 40
Water ............................................................................................................ 40
8.1 Rinsing water does not flow................................................................... 40
8.2 Water tank overflows ............................................................................. 40
8.3 Rinsing water constantly switches on and off ........................................ 40

Algae

1.1 Excessive algae growth in water tank


Algae growth inside the water tank is not only annoying, it causes increased cleaning work and leaves residue on the films. When algae growth increases, countermeasures are in demand:

When work has been completed at the end of the day, drain water out of the
machine.

Clean dryer-water rack regularly. Use soft sponge and soap to remove residue from the rollers.

Install a particle filter system in the fresh water supply for the processor.

If water tank overflows due to algae growth blocking the overflow hose, then
the overflow hose can directly be connected to the connection at the water
tank inside the machine.

If no other solutions can be found, then usage of Anti-Algae-Agents can be a


great improvement (automatic dispensers work the best). However, it is
known that cleaning agents containing chlorine may corrode rubber rollers
and high-grade steel in the tank area (check before use).

36

OPTIMAX2010

Trouble Shooting

General

2.1 Unit does not switch on

Ensure that the power socket conducts power.

Check machine fuses.

English

For replacement exclusively use PROTEC gold cap fuses.


These fuses are optimized for use under existing conditions.

While power switch is on, check the following components: Voltage on contact
of main switch - if no voltage: - change main switch. Check input voltage at
electronics. If the voltage is normal, replace the electronics. If there is no voltage: check the cable.

2.2 No display but circulation pumps run

Check input voltage of 5 V at the contacts no. 1 and 8 of the 8-pole-plug X18
from the control panel PCB. If voltage is present, then replace the control
panel.

Disconnect the temperature sensor of the developer bath (X15) and check
display again.

Drive

3.1 Film transport does not run, film processing has started

Display E1: see Error messages on page 29.

Check screwing of chain wheel on motor- and driveshaft.

3.2 Machine does not start automatically

When the machine is switched on, insert a film into the feed. If the display
shows two bars with decimal points, then at least one of the film detection
switches is in order. Check the function of both switches, replace as needed.

The display shows E1: The cover switch is not actuated by the latch on the
cover. Cover switch has no current passage when activated: Replace.

3.3 Machine doesn't stop automatically, motor and fan run continuously

Display is flashing: Control is in the manual mode. Switch back to Automatic


Mode (see page 20).

The display continuously shows two bars with decimal points: Actuator of the
film detection switch is jammed. Readjust the switch or replace it. If the
switches are defective, the machine can still be used in the manual mode (see
page 20).

The power output section may be defective, if so replace it.

3.4 Drive motor does not run

Display E1: see Error messages on page 29.

No continuity of cover switch when activated: Replace.

Check drive motor: If voltage can be detected on motor, then motor is defective.

OPTIMAX2010

37

Trouble Shooting

Baths

4.1 No circulation in bath

Circulation pump works but no circulation in bath: Air lock in heating and circulation system. Vent the pump.

Particles in the pump chamber. The pump chamber can be easily opened by
removing the four clips. When closing again ensure that the rubber seal is
positioned correctly and not damaged.

Check connection of pump, circulation pump possibly defective.

4.2 Developer temperature too high

Check attachment of temperature sensor. This should be firmly positioned on tube and completely covered with foam rubber.

Check sensor: Check voltage on sensor between pin 3 (green) and pin 2
(brown). At room temperature the tension must reach approx. 0.3 V.

If the sensor has no fault then electronic is defective.

4.3 Developer temperature too low

Check circulation pump. Air lock in the circulation pump: Ventilate pump (see
page 13). If no circulation can be detected: Check electrical connection of
recirculation pump; pump may be defective.

Bath is not heated: Check temperature safety switch on heat-exchanger.


Check heating element: impedance across the element should reach approx.
66 .

Check temperature sensor (see 4.2).

If no error can be found, then the electronics may possibly be defective.

4.4 Developer temperature too low, fixer temperature too high

Air lock in the developer circulation pump: ventilate circulation (see page 13).
4.5 Developer bath temperature too high or too low
(display shows values of 21 C or 40 C)

Check temperature sensor. Sensor is either not connected or defective.


4.6 Switch-over from C to F
The developer temperature can be displayed in either C or F.
Switch-over of temperature unit:
1.

Switch the unit off.

2.

Press and hold the buttons processing time (4) and developer temperature (5)
while switching the unit on.

3.

Select the desired unit of measure with the arrow keys (2 and 3). C for Celsius
and F for Fahrenheit.

4.

Switch the unit off to save the unit displayed.

4.7 Calibration of bath temperature /


actual bath temperature is different from displayed value
Differences between displayed temperature and measured value in the developer bath can be adjusted. An adjustment may be necessary after replacement
of a bath temperature sensor. An adjustment is recommended when the deviation exceeds 0.5 C and is mandatory if the deviation exceeds 1,5 C.

38

OPTIMAX2010

Trouble Shooting

1.

Switch the unit off. Press and hold the developer temperature button (5) and
switch the unit on. The display indicates the developer temperature measured
by the sensor in 1 degree increments.

2.

Measure the actual temperature inside the developer bath using a calibrated
thermometer.

3.

Adjust the displayed value in 1-degree-steps to the thermometer value, using


the arrow buttons (2 and 3). Display of the digit after the decimal point is activated by pressing the developer temperature button (5). Adapt the value after
the decimal point to the thermometer value, using the arrow buttons.

4.

Switch the unit off to save the calibration.

English

Calibration process

4.8 Developer level switch constantly displays UU

Observe notes under 6.1 Replenishment pump does not work or works insufficiently, page 40.

The developer level switch is not positioned correctly. The switching point is
below the developer overflow. Readjust the height of the level switch.

The level switch is defective (e.g. closed permanently).

If all of the above points are okay, replace the, control unit.

Film Defects

5.1 Films will not dry

Check the set dryer output (99 corresponds to maximum, that is full heating
output).

No air comes out of air channel: check the connections of the fan, e. g. fan
defective.

Cold air comes out of air channel: check the connections of the heating element in the air channel, the heating element may be defective (resistance
must reached approx. 45 ).

Hot air comes out of air channel, but the film is still not dried to satisfaction.
Check chemicals and film type. If this leads to no solution, then the transport
speed of the machine can be reduced.

5.2 The film does not transport correctly

Check the positioning of the racks in the machine and make sure that the
latches are closed.

Check the roller racks: Position of the guide elements, rollers are in correct
position and are not loose, flat springs are not bent, all gears are in place.

Motor runs: The worm gear of the drive shaft should be secured with a splint
to avoid twisting. Check the screws and positioning of the chain and chain
wheel.

5.3 Scratches, pressure marks, dirt on film

Straight scratches in the infeed direction indicate faulty guide elements.


Check each rack and straighten up the guide elements. If mechanically damaged, replace the guide elements.

Pressure marks caused due to polluted or damaged rollers. Check rollers for
visible damage. Rubber rollers sometimes swell up. Exchange defective rollers.

OPTIMAX2010

39

Trouble Shooting

Replenishment

6.1 Replenishment pump does not work or works insufficiently

Clean valves inside connection tube of pump.


Install valve-insert correctly: Pay attention to flow-through direction!

Check filter in the suction pipe (repl. container) and clean it if necessary.

Replenishment hose aspirates air. Check connections.

Check eccentric position. Flow rate is 240 ml/min at maximum eccenter position 100%.

(60 Hz: 240 ml/min at 85 %!)

Measure the voltage at the connection X6 (replenishment pump) on the power


output section while the replenishment is switched on (in manual mode). If no
voltage can be registered - replace the power section PCB. Remark: 2 pump
version: developer replenishment pump at X6 and fixer replenishment pump
at X5.

Dryer

7.1 Dryer fan does not run or runs with too low speed

Check the correct connecting of the fan cables: bl = blue; bk = black; br =


brown.

If the fan supply lines have been transposed, the dryer fan will run at half the
nominal output only.

Water

8.1 Rinsing water does not flow

The water pressure in the water supply system is too low: Minimum pressure
2 bar (29 psi).

The valve opens, but no water flows through: filter at inflow is blocked.

Check the green water inlet hose inside the machine.

The water level switch is not positioned correctly: switching point is too low
(below the overflow level), therefore no fresh water is supplied.

The level switch is defective (e. g. permanently open).

Start the unit in manual mode and measure the voltage at the connection X4.
If no voltage can be registered, replace the power output section PCB.

8.2 Water tank overflows

Water drainage hose (overflow) should have a constant fall. The hose end
should be positioned above the drainage level in the syphon.

Check water drain opening in the tank and the hose for blockage and residues.

When extreme algae growth is noticed, the overflow can be connected


directly at the back of the water tank.

8.3 Rinsing water constantly switches on and off

At regular intervals (approx. 1 minute on and 1 minute off): The water saving
mode has been activated.

40

At short intervals: th level switch is not positioned correctly (exactly on the


overflow level). Insert the rack. If the error continues to occur, readjust the
height of the level switch.

OPTIMAX2010

Spare Parts

English

10

11

7
6

Pos.

Order No.

Description:

1160-0-0200

Cover complete

2006-0-0005

Drain stop cock 10 mm

1170-0-2000

Replenishment tank 12 l dev.

1170-0-2100

Replenishment tank 12 l fix.

1170-0-1760

Suction pipe with filter for 12l tank, round

2004-0-0010

Electrical power lead 220-240 V

2004-0-0021

Electrical power lead 220-240 V

2018-0-0001

Water inlet tube

1267-0-0030

Processor stand

1267-0-0040

Closed base cabinet

1101-0-2000

Replenishment tank 25 l dev.

1101-0-2100

Replenishment tank 25 l fix.

10

1101-0-1700

Suction pipe with filter for 25l tank

11

1101-0-4100

Floating cover developer

2018-0-0012

Hose 10 x 2 mm, clear, reinforced

2018-0-0009

Hose 10 x 2 mm, blue, reinforced

2018-0-0008

Hose 10 x 2 mm, red, reinforced

2018-0-0005

Hose 4 x 1 mm, green

2018-0-0021

Hose 9 x 2 mm, red, transparent

2018-0-0022

Hose 9 x 2 mm, blue, transparent

2022-0-0014

Tube clamp Snap

2022-0-0019

Wire tube clamp

2022-0-0027

Wire tube clamp

2022-0-0028

Wire tube clamp

2022-0-0005

Wire tube clamp

1101-0-4600

Floating balls, 300 pcs.

1101-0-4800

Floating balls, 200 pcs.

OPTIMAX2010

41

Spare Parts

28
(52)

(20b)

20b

21

20a
(30)

26
27
20

25
20
23 22

Pos.

Order No.

Description:

20

0202-1-0008

Replenishment pump 2KBA, 220-240 V, 50/60 Hz

0202-6-0008

Replenishment pump 2KBA, 115 V, 50/60 Hz

20a

0002-1-0008

Conical valve f. pos 20

20b

0202-5-0002

Replenishment pump KBR-3X, 220-240 V, 50/60 Hz

0202-6-0002

Replenishment pump KBR-3X, 115 V, 50/60 Hz

2002-1-0016

Circulation pump 220-240 V, 50/60 Hz

2002-6-0016

Circulation pump 110 V, 50/60 Hz

2028-0-0023

Main switch 220-240 V

2028-0-0036

Main switch 110 V UL

23

2010-0-0004

Fuse holder

2010-0-0010

Fuse slow blow in gold, T 10A/250V

2007-0-0004

Cover for fuse holder

22+23

2028-0-0036

Device switch, therm. 110-120 V UL

24

1160-0-0702

Angle connection (aluminium)

25

0160-5-1300

Electronics 220-240 V

0160-6-1300

Electronics 110-120 V

1160-0-0705

PVC panel (control unit)

26

0170-0-2400

Micro switch (Cover)

0170-4-2400

Micro switch (Cover) UL

21
22

27

2007-0-0010

Actuator f. micro switch

28

2021-0-0001

Screw-in connector

42

24

OPTIMAX2010

Spare Parts
34

38

33

32

37

English

35

31

35

30

40
39

Pos.
30

31

Order No.

Description:

2001-1-0004

Main drive motor 220-240 V, 50 Hz

2001-2-0004

Main drive motor 220-240 V, 60 Hz

2001-6-0004

Main drive motor 120 V, 50/60 Hz

1170-0-1101

Motor bracket

32

1170-0-1501

Drive shaft worm-gear

33

1170-0-1503

Worm-gear

34

1170-0-1502

Bearing block

35

1170-0-1506

Chain wheel t=12

1170-0-1504

Chain wheel t=14

1170-0-1505

Chain wheel t=16

1170-0-1102

Chain wheel t=17

1170-0-1507

Chain wheel t=18

37

2037-0-0002

Chain 6 mm with coupler link

38

3000-9-4013

Split pin 2.0 x 20 mm, A4

39

2012-0-0013

Level switch

40

1120-0-1502

Bracket for level switch

OPTIMAX2010

43

Spare Parts
54
50
62
63
53

51
Housing

61
64

56

57
58

55

52

59
Pos.

Order No.

Description:

50

1170-0-1301

Air channel

51

0170-0-1300

Heating element 230 V, 1100 W

0170-6-1310

Heating element 110 V, 900 W

2008-5-0007

Dryer fan 220-240 V, 50/60 Hz

2008-6-0007

Dryer fan 115 V, 50/60 Hz

1160-5-1900

Solenoid valve 220-240 V, 50/60 Hz

1160-6-1900

Solenoid valve 115 V, 50/60 Hz

54

2007-0-0015

Film detection switch

55

1160-0-0105

Film feed tray

56

2003-5-0002

Heating element 230 V, 800 W

2003-6-0002

Heating element 120 V, 400 W

57

1130-0-2101

Heat exchanger

58

2005-0-0005

Temperature safety switch mounted on heat exchanger

59

0190-0-2200

Temperature sensor

61

1170-0-1302

Channel dryer heating

62

1160-0-0801

Support bracket for film detection switch

63

2027-0-0012

Strain relief

64

1160-0-0710

Hose stub, rubber

52
53

44

OPTIMAX2010

Spare Parts

100

English

103

112

108
111
102

113
117

104

110
121
119

114

120

115
116

109

122

103
123
106
107

105

104

104
Standard roller racks

OPTIMAX2010

45

Spare Parts
Pos.

Order No.

Description:
Standard Processor

1170-0-0300

Roller rack, developer

1170-0-0400

Roller rack, fixer

1170-0-0600

Roller rack, dryer


Mammography Processor

1171-0-0600

Roller rack, dryer


Graphic Arts Processor

1172-0-0300

Roller rack, developer

1172-0-0600

Roller rack, dryer

100

0170-0-0301

Dryer side plate left w. shafts

1170-0-0301

Side plate, dev. (right)

0170-0-0401

Dryer side plate left w. shafts (left)

1170-0-0401

Side plate fix. (right)

102

1140-0-3800

Guide bar straight, short

103

1140-0-4500

Guide bar with nose

104

1140-0-3700

Guide bar, curved

105

1170-0-0304

Flat spring 55

106

3079-8-5013

Screw M4x10, A4

107

3009-3-4023

Hexagon nut M4, A4

108

1140-0-0301

PU-roller 35 ground

109

1170-0-0310

Drive shaft rack

110

1101-0-0302

Gear t = 16, D-hole

111

1101-0-0304

Gear t = 32, round hole

112

1101-0-0303

Gear t = 32, D-hole

113

1170-0-0302

Worm wheel

114

1101-0-0305

Bearing bush

115

1101-0-0317

Bearing bush, black

116

2014-0-0001

Circlip

117

0170-0-0601

Dryer side plate left w. shafts

1170-0-0602

Dryer side plate right

119

1140-0-0302

Rubber roller 35

120

1140-0-0605

Air jet (35)

121

1170-0-0604

Dryer plate, large

122

1170-0-0603

Dryer plate, small

123

1170-0-0303

Flat spring 35

131

130

46

The light protection cover can be removed. This is necessary to gain access to the
film detection switches and the developer level switch. To remove it, pull off the blind
(131) on the right side (!) of the cover and then pull the indexing bolt (130) from the
support toward the inside. The cover can now be removed to the top. Remark: The
left indexing bolt remains completely installed.

OPTIMAX2010

Spare Parts
132

133

Guide slot

Pos.

Order No.

Description:

130

1160-0-3103

Indexing bolt

131

1160-0-3106

Blind for light protection cover

132

2011-0-0137

Control panel foil

2011-0-0139

Operating membrane, 2 pump version

133

0160-9-1200

Control panel

Once the operating panel PCB has been


removed, the control unit can be
removed. Please do not lift the control unit
out further than shown in the illustration. A
guide on the top edge allows to position
the control unit for service purposes.

Tips and Tricks


Removal of control PCB
To reach the screws of the control PCB, remove the film covering the buttons by
approx 20 mm on the top and bottom edges (lift it, see illustration top left).

Stop start-cycle
The start-cycle (after switching the machine on) can be manually interrupted. To
stop start-cycle, press both arrow-buttons (2+3) simultaneously. The start-cycle
may only be interrupted for service purposes.

Display of machine information


When during the start-up cycle one of the arrow-buttons is pressed then various
machine information will be displayed.
Arrow button Up:
The software version is displayed as long as you press the button.
Arrow button Down:
The number of film cycles is displayed as long as you press the button. Not the decimal point. Since the display has two digits only, the value needs to be converted:
XX : value x 10 = number of films
XX. : value x 100 = number of films
X.X : value x 1,000 = number of films
X.X. :value x 10,000= number of films
9.9. : more than 990,000 films

OPTIMAX2010

47

English

Attention!
The heat sink is not
earthed!

48

Halter Hauptschalter
Bracket Main Switch

Umwlzpumpe
circulation pump
Motor
motor

Wrmetauscher
heat exchanger

Filmeinlaufblech
film infeet plate

Pumpenplatte
pump plate

Abdeckung Bedienteil
cover control PCB

Gehuseboden
body bottom plate

Luftschacht
air channel

Sicherung
2xT10A/250V
fuse
slow blow
2x 10A/250V

Ausschalter
main
switch

X1

Umwlzpumpe
circul.Pump

X2

X17

X15

Badtemp.
bathtemp.

X14

Motordrehzahl
variable
speed
motor

X13

X3

Geblse
dryer fan

X5

X6

Regenerierpumpe
Replenishment pump

Zweite Regenerierpumpe
second
Replenishment pump

Magnetventil
solenoidvalve

X4

1 pump version:
X6=FIX+DEV
2 pumps version:
X5=FIX, X6=DEV

(1160-5-1300)

X8

Badheizung
bathheating

Trocknerheizung
dryerheating

X7

X10

B1
B2
B3
B4
B5
B6
B7
B8

Temp.begrenzer
temp.limitor

serielle
Schnittstelle

Wrmetauscher
exchanger

Motor
motor

X9

Niveau
Entwickler
niveau
developer

X12 X11

1. Filmerfassung
1. Filminfeet

Leistungssteuerteil
Power PCB

X16

bk
br
bl

Niveau
Wasser
niveau
water

2. Filmerfassung
2. Filminfeet

Zust.

nderung

Datum Name

Diese Zeichnung ist ausschlielich unser Eigentum.


Ohne unsere vorherige Zustimmung darf sie weder
vervielfltigt noch Dritten zugnglich gemacht werden.
Wir behalten uns alle Rechte vor, auch fr den Fall der
Patenterteilung oder Gebrauchsmustereintragung.

Datum
Name
Bearb. 15.11.01 DK
Gepr.
Norm

DIN ISO
2768 T1-m

B1
B2
B3
B4
B5
B6
B7
B8

Stromlaufplan
current flow chart

Optimax 2010

Mastab 1:1

(1160-9-1200)

Bediensteuerteil
control PCB

Blatt
1
1
Bl.

Electric Diagrams

OPTIMAX2010

English

Electric Diagrams

OPTIMAX2010

49

Electric Diagrams

50

OPTIMAX2010

English

Electric Diagrams

OPTIMAX2010

51

Electric Diagrams

52

OPTIMAX2010

Differences between OPTIMAX 2010 Standard (1160-1-0000)


and OPTIMAX 2010 with two pumps (1160-1-2000)

English

1. Control panel
Display working parameters

! Arrow button Up = increase parameter value


" Arrow button down = decrease parameter value
Mode Buttons

# Processing time in minutes


$ Developer temperature in C
% Dryer output in %
& Replenishment time developer
' Replenishment time fixer

2. Replenishment time
The replenishment function and adjustment of the replenishment time are identical with the standard version.

7
D
E
V

F
I
X

Power on Autofill

Enter Memory
Recall

Store

Exit

3. Spare Parts List


1.

In the service manual page 42, pos. 20: replenishment


pump with bellows: 0202-5-0002 (pos. 20b).

2.

EPROM: 1160-0-0001

OPTIMAX2010

53

OPTIMAX 2010 NDT


Order No. 1163 - X - Y000
X:

50 Hz

60 Hz

Y:

Version with 1 pump

Version with 2 pumps

The film developer OPTIMAX2010 has been extended by a further unit version.
Introduction
Processing time and developer temperature of the OPTIMAX2010 NDT processor
have been adjusted to the requirements of NDT-films. This results in the following
modifications compared with the OPTIMAX2010 standard version.
General
To maintain constantly good film quality the NDT-roller (upper roller of last roller pair
of developer rack) must be replaced every 3 - 6 months, depending on the quantity
of films processed, the chemicals and films used. 1 spare roller is supplied with the
unit. This roller must be considered a wear part and is excluded from the guarantee.
Important!
Please take care that the film does not carry any dirt into the
processor.
Technical Specifications (compare page 8)
Processing capacity:

129 films 24x30 cm (crosswise), at lowest


processing time

Process time:

1.5 - 10 min

Linear speed:

8.4 - 56.0 cm/min

Developer time:

25-164 s

Developer temperature

26 - 37 C / 78 - 99 F

Processing time (compare page 17)


Processing time from 1.5 - 10.0 min
Processing and developer time relation
Processing time (min)
1,5
1,7
2,0
2,3
2,5
2,7
3,0
5,0
8,0
10,0

Developer time (s)


25
28
33
38
41
44
49
82
131
164

Infeed speed (cm/min)


56
49
42
37
34
31
28
17
11
9

Developer temperature (compare page 18)


Adjustable 26 - 37 C / 78 - 99 F)

54

OPTIMAX2010

OPTIMAX 2010 NDT


Pos.

Order No.

Description:

25
124
125
126
127

0163-5-1300
0163-6-1300
1163-0-0300
1163-0-0400
1163-0-0600
1163-0-0307
1161-0-3900
1161-0-4000
1101-0-0317

Power output section OPTIMAX 2010 NDT 230V


Power output section OPTIMAX 2010 NDT 110V
Roller rack developer NDT
Roller rack fixer NDT
Roller rack water/dryer NDT
Roller NDT (output roller top of developer rack)
Guide rail 2, bent without ribs
Guide rail 2, bent with nose, without ribs
Bearing bush, large, black

Developer (red)

English

Spare parts list (compare page 41)

Fixer (blue)

Water/dryer (beige)
125

Guide rail 2, bent without ribs


1101-0-3900

126

Guide rail 2, bent with nose, without ribs


1101-0-4000

127

Bearing bush, large, black


1101-0-0317

124

Roller NDT
1163-0-0307

OPTIMAX2010

55

56

OPTIMAX2010